Adhesive material



F6). 4, D, J BUCKLEY 51- AL ADHESIVE MATERIAL Filed Oct. 30, 1942 Q '1 42 47 2 we, 1

INVENTORS. DONALD J Baa/as) By Roaznr L. Snnw or uncoated side of the fabric, it has been proi atenteci Feb. 4, i947 ADHESIVE MATERIAL Donald J. Buckley, North Plainfleld, N. J., and

Robert L. Smith, Otego, N. Y., assig'nors to Industrial Tape Corporation, North Brunswick, N. J., a corporation of New Jersey Application October 30, 1942, Serial No. 463,900

Claims. (Cl. 117-76) This invention relates to adhesive materials of be the possibility that such vulcanizing agents as the character having a flexible woven fabric backwere not utilized in the vulcanizing process would ing with a normally tacky adhesive united theremigrate into the adhesive mass, tending to vulto, as for instance, pressure sensitive tapes for canize the latter and rendering the tape unfit use as surgical dressings, insulating wrappings, 5 for use in a comparatively short period of time. decorative and other wall coverings, and for many In accordance with the present invention there other purposes. 7 is provided an adhesive material comprising a In the manufacture of such tapes it has been flexible woven fabric and a pressure sensitive adthe custom to apply the adhesive mass to the hesive with an interposed barrier coat containing woven fabric either bycalendering the mass di- 10 a polyaliphaticolefin as, for instance, polyisorectly on to one surface thereof or by coating the butylene which is sold under the trade names surface with a dispersion or solution containing Vistanex and Synthetic 100, and a large prothe mass and then evaporating the solvent. Reportion of filler, the barrier coat being deposited gardless of the process used, however, a good tape on one surface of the fabric prior to the applicaas heretofore made required that the mass be tion of the adhesive mass. While the improved worked into the interstices of the fabric to anbarrier coat may be calendered on to the surface chor the backing and the mass together, thus to of the fabric, it is preferred to disperse the polyavoid separation of the mass and the fabric as isobutylene and the filler together with other mathe tape is stripped from the roll in which it is terials referred to hereinafter, in a suitable solusually wound, or to prevent retention of the 2 vent, spread the solution evenly on the surface mass on the surface to which the tape has been of the fabric backing, and then evaporate the applied in use, should it become necessary to strip solvent, thereby leaving on said surface a thin, the tape from the surface after it has served its uniform, unbroken film com osed of the materials intended purpose. Just mentioned. While the film will adhere firmly It is Obvious t w e t s s pplied dito the surface of the fabric and also to the adrectly to a fabric backing, a large portion of it hesive mass when the latter subsequently is apserves merely to anchor the mass to the fabric plied, nevertheless it does not enter into the inand is not effective as an adhesive in securing the terstices of the fabric and, as it possesses a certape in place. In other words, the portion of the tain amount of tensile strength, it will not be adhesive mass embedded in the interstices of the broken either during the application of the adfabric does not aid in causing the tape to adhere hesive or when subsequently the tape is applied $0 the Surface to Which it is pplied. Since the to a surface in use. Thus under all normal cir- Bdhesive masses usually used Contain a large cumstances either during the manufacture of the P ta e of u er which s expensive. in itself tape or in service, the barrier coat will effectively and expensive also to process to a condition suitprevent the adhesive mass frgm entering the able for use as an adhesive, the resultant tape is gerstices of th fabric,

relatively high in cost. Polyisobutylene, the referred film forming n s sta c it is undesirable to have constituent, can be manufactured with molecuthe adhesive mass penetrate the fabric and some l weight ranging f o a low of b t six thoutapes have been made with that in view but it has sand 0 0 or less t a high of about t h been found that the slight pressure within a, roll d th a d (200,000), and, depending upon S tape is sufficient (in the absence of some the molecular weight, the material possesses difmeans of preventing it) to cause penetration of ferent degrees of plasticity that of the lower the adhesive into the fabric with the result that molecular w ights having a high degree of pla after a sh rt period, th ta s s u f its ticity characterized by a substantial amount of efl'ectivenesscold flow, whereas that of the higher molecular Mainly for the purpose. of Preventing the weights has a low degree of plasticity characterhesive mass from permeating through to the back ized by being relatively t1fl When polyisobutylene is used as the film formposed to place between the fabric and the layer m constituent, a selected portion only of it adhesive, an intermediate coating composed of range of molecular weights is preferred. In other a suitable rubber composition which, when vulwords, the m forming material should t be canized, will serve to prevent the adhesive from so soft or plastic as to lack the necessary firm- Da 111150 the f c's interstices- While that ness to serve as a barrier coat, whereas, on the e pe might ct a a in n the amount other hand, it should not be so stifi as to interof adhesive used, it would effect no a in n fere with the flexibility of the finished tape or cost; indeed it might result in a more expensive to lack the properties of taking up the desired product because of the degree to which the rubamount of filler. Polyisobutylene in the range r p und would hav to b p ssed, parof molecular weights from eighty thousand ticularly if it contained afiller. There would also (80,000), to one hundred twenty thousand (120,-

000) may be utilized to the best advantage although this range is not given by way of limitation since in actuality the type of polyisobutyl ene selected will depend to some extent upon the amount of filler it is desired the film should contain and upon other considerations which will be readily apparent to those skilled in the art.

Among the advantages of polyis b ty e in so far as this invention is concerned is its ability to be heavily loaded with a filler without a 'resultant loss in plasticity as would be the case if rubber were used with the same amount of filler because of the extent to which the rubber would have to be milled in the compounding process. Furthermore, since there are no vulcanizing or accelerating agents present in the film as it is applied to the fabric backing, the danger of migration of such agents into the adhesive mass is nonexistent. Other advantages in the use of polyisobutylene are its excellent aging characteristics, its resistance to oxidation, its excellent electrical characteristics, its ability to resist the action of many organic solvents and acids, and its low water absorption.

While many fillers could be used with polyisobutylene in the manufacture of the improved barrier coat, Witco clay #2 is preferred. This clay is well known to those in the rubber industry and is characterized by its purity and by its low oil absorption and correspondingly low "drying action. The clay filler imparts firmness to the barrier coat and renders it low in cost because of the large amount that can be used with the suggested film material.

For the purpose of anchoring the barrier coat to the fabric backing and for the purpose also of presenting a surface to which the adhesive mass will readily adhere, a nonoxidizing resin compatible with the film forming material and also with the adhesive mass is used in the barrier coat compound. By way of example, ester gum is suggested as well as the hydrogenated rosin Staybelite or esters thereof or the modified rosin Galex, the principal constituent of which is dehydroabletic acid.

As previously stated, the barrier coat may be calendered on the fabric or it may be laid down upon the fabric in the form of a solution. Any suitable solvent may be used, toluene, heptane, hexane and benzene being suggested byway of example.

Regarding the adhesive, any of the pressure sensitive adhesive masses, as, for instance, those containing crude rubber or reclaimed rubber, may be used. These masses may be calendered onto the barrier coat or spread on in the form of a dispersion in a suitable solvent which is later evaporated.

In actual practice, excellent adhesive tapes have been manufactured with a barrier coat of the following composition which is given purely by way of example:

Example Parts Polyisobutylene (molecular weight about 100,000) 300 Witco clay #2 600 Ester gum 120 Lanolln 4 Solvent (toluene) 606 The polyisobutylene, the Witco clay #2 and the lanolin were compounded in a Banbury mixer. This compound was then dispersed with the ester gum and the solvent in an internal mixer. This mixture then was spread upon the surface of a cloth backing of the square woven variety having 80 threads to the inch both ways, and the solvent evaporated. One ounce of the mixture (dry weight) was used per square yard. The barrier coated cloth was then coated with three ounces er square yard of adhesive mass. When it is considered that an adhesive material without a barrier coat but having the same adhesive properties would require from five to six ounces of adhesive mass per square. yard, the excess over three ounces serving merely to anchor the mass to the fabric, the substantial savings that can be effected by the practice of the invention will be manifest.

It will be understood, of course. that the proportions in the example given above could be varied over a substantial range. Thus, with reference to the polyisobutylene, the clay and ester gum could be varied at least plus and minus twenty percent and ten percent respectively. Variations in the character of the polyisobutylene would permit of further variations in the proportions ofthe other ingredients used.

Referring to the drawing:

Fig. 1 is a, plan view of an adhesive tape in which the present improvements are incorporated, the upper layers of the tape being broken away to show the layer next below; and

Fig. 2 is an enlarged cross-sectional view of the ,adhesive tape shown in Fig. 1.

In the different figures there is shown a flexible woven fabric backing member A filmed with a barrier coat B to which a layer C of adhesive mass has been applied. As shown in Fig. 2 the barrier coat B spans orbridges the gaps between the threads of the backing member and does not enter into the interstices thereof. In other words, the barrier coat is substantially uniform in thickness and presents a surface which deviates only slightly from what otherwise would be a relatively flat surface and to which the layer of adhesive mass will readily adhere. A barrier coat of this character will insure an adhesive layer of substantially uniform thickness. Furthermore, the layer C in its entirety will function as an adhesive, no portion thereof being utilized for any other purpose as, for instance, to anchor the mass to the fabric backing as would be the case in the absence of a barrier coat.

An adhesive tape made in accordance with the present improvements has greater tensile strength than a tape made from the same backing material but devoid of a barrier coat. It would seem that the tensile strength of the barrier coat and of the backing'member are additive in effect. In addition, there are economies derived from a saving in the amount of adhesive used, which is relatively expensive, and from a. saving in the cost of processing, at least if the improved tape, as regards the latter factor, be compared with other tapes having a barrier coat which has to be subjected to a process of vulcanizing.

From the foregoing description, it will be apparent that the instant invention may be subject to many modifications or changes within its scope. It will be understood, therefore, that the invention is to be limited only by the prior art and the appended claims.

Having thus described the invention, what is claimed is:

1. As an article of manufacture, an adhesive material having a flexible backing presenting interstices throughout at least one of its surfaces, a. normally tacky pressure-sensitive adhesive mass 5 united to the surface presenting the interstices, and a firm yet flexible and substantially, nontacky intermediate barrier layer presenting a uniform surface to receive the adhesive mass and serving to prevent said mass from entering the interstices of the backing, said barrier layer comprising major proportions of polyisobutylene and a filler inert to the adhesive mass.

.2. As an article of manufacture, an adhesive material having a flexible backing presenting interstices throughout at least one of its surfaces, a normallytacky pressure-sensitive adhesive mass united to the surface presenting the interstices, and a flrm'yet flexible and substantially non-tacky intermediate barrier layer presenting a uniform surface to receive the adhesive mass and serving to prevent said mass from entering the interstices of the backing, said barrier layer comprising polyisobutylene, a filler inert to the adhesive mass, and a compatible non-oxidizing resin.

3. As an article of manufacture, an adhesive material having a flexible backing presenting interstices throughout at least one of its surfaces, a normally tacky pressure-sensitive adhesive mass united to the surface presenting the interstices, and a firm yet flexible and substantially non-tacky intermediate barrier layer presenting a uniform surface to receive the adhesive mass and serving to prevent said mass from entering the interstices of the backing, said barrier layer comprising polyisobutylene, a filler inert to the adhesive mass and a, non-oxidizing adhesive augmenting resin compatible with the polyisobutylene and with the pressure-sensitive adhesive mass.

4. As an article of manufacture, an adhesive material having a flexible backing presenting interstices throughout at least one of its surfaces, a normally tacky pressure-sensitive adhesive mass united to the surface presenting the interstices, and a firm yet flexible and substantially non-tacky intermediate barrier layer presenting a uniform surface to receive the adhesive mass and serving to prevent said mass from entering the interstices of the backing, said barrier layer comprising polyisobutylene having a molecular weight in the range 80,000 to 120,000, filler inert serving to prevent said mass from entering the interstices of the backing, said barrier layer comprising polyisobutylene and a clay filler in excess of the pglyisobutylene by a substantial amount.

DONALD J. BUCKLEY. ROBERT L. SMITH.

REFERENCES CITED The following references are of record in the flle of this patent:

UNITED STATES PA'I'ENTS Number Name Date 2,269,214 Luitwieler Jan. 6, 1942 2,142,039 Abrams, et al. Dec. 27, 1938 2,352,463 Wenzelberger June 27, 1944 2,142,039 Abrams, et al. Dec. 27, 1938 FOREIGN PATENTS Number Country Date 377,572 British .1 July 28, 1932 OTHER REFERENCES Vistanex Polybutene: Published by Advance Solvents and Chemical Corp. (New York), Nov. 12, 1940.

Paper Coatings and Adhesives: Published by -Advance Solvents 8: Chemical Corp. (N. Y.)

Recd in Div. 38 Nov. 5, 1941. Copies in II'I-RLP.

Ex parte Hill 1924 C. D. 21; O. G. 707. Naamlooze v. Coe 545 O. G. 675, Smith v. Nichols 88, U. B. 112. 

